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AWE Tuning Audi TT RS Build Thread

AWE Tuning has taken the TT RS under its wing. This particular TT RS has already gained some attention through the development of the AWE Tuning SwitchPath™ exhaust, though here’s a bit more detail, all in one place, for your viewing pleasure.

The car arrived at AWE Tuning HQ as a stock TT RS (impressive in its own right), but that was about to get better.

The Baseline
We put it on our in-house dyno to get some baseline numbers. Keep in mind, different dynos read differently – this is the same AWD Mustang Dyno that AWE Tuning uses for all development, to keep things consistent.

Getting Measurements
So off it went onto a lift for measurements and prototyping. The TT RS is no slouch from the factory, but a quick look around inspired confidence. We knew that we could do better.
Like all of our systems, we started out by taking measurements of the stock exhaust to ensure that our prototype exhaust retained OEM fitment.

Over the next week or so, we’ll be releasing tidbits about the catalog, culminating in the release of the comprehensive TT RS line, by AWE Tuning.
So stay tuned, this is a good one!

PS: Quick shout out to our friends at BlownEuros for some of the shots you’ll see in this thread.

The SwitchPath™ Exhaust
We measured and re-measured to ensure that everything would have an OEM quality and fitment. Once that was done, ‘twas prototype time.

The TT RS was determined to be a great platform for the AWE Tuning SwitchPath system. The SwitchPath system until this point had been used only on the Audi R8, but we felt that due to complaints about the tone of the TT RS in sport mode at highway speeds, a SwitchPath system with options would make a lot of sense for the TT RS.

The difference on the TT RS system versus the R8 would be that the R8 valves on the AWE Tuning SwitchPath are triggered by throttle level, whereas the TT RS valves open based upon boost levels. Translation: This was a new SwitchPath model all together.

The result: A new-for-the-TT RS SwitchPath system, which made the engine sing a little louder, and sound a little sweeter (and along the way, a system that lost some weight – to the tune of 9.5lbs less than the stock unit).

The SwitchPath Activator

While AWE Tuning’s master fabricators were prototyping the Exhaust and Cat Deletes (Cat Deletes to be covered later in this thread), AWE Tuning engineers were hard at work on the in-cabin AWE Tuning SwitchPath Activator. A new SwitchPath Activator was designed with the TT RS in mind that would enable the SwitchPath system to work independently of the Sport button.

We envisioned a sleek control module that was not only simple to operate, but integrated elegantly within the cabin so that to the untrained eye it felt right at home.

By placing the AWE Tuning SwitchPath Activator in the ashtray, we were able to achieve our goal of seamless cabin integration. Smoker? The AWE Tuning SwitchPath system is your reason to quit.

So here’s the bottom line: This system is ready for business when you want it to be, and ready for a business meeting when you don’t. It’s truly the best of both worlds. And man, is that SwitchPath Activator button addictive.

All in all, this now one of our finest systems to date. It will retail for $2899, which will include the SwitchPath exhaust system as well as the in-cabin SwitchPath Activator. More, right here.
Stay tuned, we’re going to make this TT RS even more aggressive tomorrow…

Bad news for cat lovers.
The TT RS sounded good, but there’s a contingent that felt that another option was required. Enter the AWE Tuning Cat-Delete pipes. The best part about them, (aside from the sound and power), is that with OEM-quality fitment, the AWE Tuning Cat-Deletes can be used with the stock TT RS system.

With the new Cat-Deletes in place, the car was strapped onto AWE Tuning’s in-house AWD mustang dyno. Max gains were seen to the tune of 11hp and 15tq, with peak gains of 7hp and 8tq.
Dyno sheets below:

And some video, which is worth a million words:

This will be launched with the rest of our TT RS catalog and retail for $309. More information can be found here

And we’re not done yet. Stay tuned for more – coming up, intercoolers, wheels and of course, some software to take it to the finish line.

While doing street and dyno logging, we noticed some nice opportunity ahead due to higher intake air temperatures than we like to see. The TT RS needed a larger Front Mounted Intercooler before it could safely and efficiently make more power.

As you see here, the crash bar on the TT RS hangs out in a very “inopportune” location. The style of intercooler we’ve engineered for the A4, A5 and Q5 would not work on the TT RS. AWE Tuning operates at the intersection of practicality and performance – so hacking was not an option.

The AWE Tuning engineering team was going in.
We decided to make our Intercooler rectangular much like the stock one, but significantly thicker to improve cooling. Our final dimensions are 6 x 5.785 x 22” without including the end tanks. Translation: 80% more cooling area.

End tanks

Intercooler end tanks were CNC’d out of a solid block of aluminum to ensure the maximum amount of strength, smooth airflow and to guarantee no leaks.

With the new intercooler in place, we strapped the TT RS back onto the in-house dyno for a few more pulls. Not only did we see max gains of 17hp/17tq at the crank, but we also lowered Intake Air Temperatures (IATs) by 22 °F, on stock software. This is a big push in the right direction, and will set the stage for big gains from G.I.A.C. software. When released, the AWE TT RS Front Mount Intercooler will retail for $1499.

Wheels

Meanwhile, HRE P40 wheels were added to the mix. Not only are they lighter than the stock wheels, but they add some distinction. We approve.

Thanks for your interest everyone! The AWE Tuning TT RS Front Mount Intercooler will not require any modifications. It is a simple bolt on AWE Tuning performance upgrade that utilizes factory hoses, designed to work perfectly without modifying any factory safety equipment. Core and end tank assembly is included, of course along with all necessary installation hardware.

The TT RS end tanks as noted are CNC machined from a single block of 6061 aluminum, and are quite significant to ensure the smoothest flow possible, utilizing a high efficiency bar and plate intercooler core.

The hp gains were significant- max gains of 17hp @6150rpm, and torque was increased by 17tq max @4050rpm, while IATs were lowered by 22 degrees F. We also saw a .8psi decrease in pressure drop (-73%) over stock. As with all AWE Tuning products, there will be no CEL when running our intercooler. Guaranteed.

Stay tuned for more as we roll out more from the TT RS catalog, for the pending release later this week!

And while your at it, why not design a FMIC for maximum eficiency by removing the crash bar so you can get a taller core in. I for one am used to this being a pivitol factor in just about every car I have modified. Im sure there will be buyers if you make it. If not, im sure others will jump on it...

And while your at it, why not design a FMIC for maximum eficiency by removing the crash bar so you can get a taller core in. I for one am used to this being a pivitol factor in just about every car I have modified. Im sure there will be buyers if you make it. If not, im sure others will jump on it...

I don't understand why people would trade the crash bar for a slightly taller IC on a street car.